An operator conducting routine rounds noted a slightly low oil level on the journal bearing housing of a large electric motor in continuous service. The well-intentioned operator proceeded to use a top-up container on hand, labeled as the appropriate product, to return the oil level to the correct level.

On a subsequent round, the operator noticed fumes as well as a loud rumbling noise that appeared to be generated by that same bearing housing. Based on that visual inspection and supported by increasing vibration levels reported by the continuous monitoring equipment, the fan was removed from service. Unfortunately, upon closer inspection it was determined that severe damage had already occurred; the motor required a major overhaul.

Analysis of the remaining oil in the top-up container used to refill the bearing housing indicated moisture levels approaching 50 percent. Severe moisture contamination introduced during top-up no doubt prevented the formation of an effective lubricating film, and therefore resulted in massive and rapid bearing damage from metal to metal contact.

Since this event, we have replaced all of the top-up containers at our facility with sealable plastic types to prevent large-scale moisture contamination. We consider this expense to be inexpensive insurance against future failures of this type.

(Noyan Ercan, Reliability Engineer, Shell Refining Australia)

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From the book Lubrication Fundamentals

As a general rule, lubricants in containers smaller than drums (550-, 390- and 16-gallon oil drums and 400- and 120-pound grease drums) should never be stored out-of-doors. When drums must be stored outside, a temporary shelter, leanto or a waterproof tarp will protect them from rain or snow. Drums should be laid on their sides with the bungs approximately horizontal. In this position, the bungs are below the level of the contents so that breathing of water or moisture is greatly reduced, and water cannot collect inside the chime. For maximum protection, the drums should be stood on end with the bung ends down on a well-drained surface.

More about Lubrication Fundamentals

Faced with increased foreign competition and decreasing profit margins, many companies have focused on preventive/predictive maintenance programs in an effort to reduce manufacturing costs.

While these efforts have brought reliability improvements, they overlook a key component in a complete reliability program – operator participation. Operators work in facilities around the clock and are the best first line of defense for early identification of potential catastrophic failures.

Do your operators own the equipment and take responsibility for how well it runs?

Hear Chris Hykin of International Paper outline a comprehensive program to get an operator-driven reliability program off the ground in his case study presentation at Lean Manufacturing 2005, Oct. 2-5 in Cleveland, OH.

His presentation will include "how-to" elements for gaining management support and operator buy-in, identifying critical program tools, route building, training and implementation, keeping the program evergreen and future improvement.

Download full Lean Manufacturing 2005 conference details.